Uniloy is proud to introduce this month’s web posting detailing AC Variable Frequency Drive Retrofits
now available for your Uniloy blowmolding equipment. ACVF drives are available for your 250R1,
and any 350R or 400R series machine. Variable frequency drive retrofits are also available for Uniloy
downstream equipment such as cooling beds and impact trimmers.
The Extruder Drive
Uniloy offers two brands of Drive Controller for the extruder drive: The Rockwell Power Flex and the
Yaskawa. Both drives are available in 50, 75, 100, and 125 horse power, and both are incorporated
within complete comprehensive retrofit packages. The Uniloy ACVF Drive package includes all of the
components needed to equip your Recip machine.
Benefits include:
 Energy savings due to higher efficiencies and power factors over the entire speed range
significantly reducing operating costs.
 No water cooling eliminates the clutch cooling, clutch cooling tank, and pump. Elimination of the
clutch cooling system reduces maintenance and energy costs in addition to lowering chiller
system demands.
 Variable frequency drives provide quiet, smooth operation.
 Electronic overload protection helps to prevent costly motor damage and downtime.
___________________________________________________________________________________________________________
Uniloy, a division of Milacron Marketing Company LLC
5550 Occidental Hwy ■ Tecumseh, MI 49286 ■ Tel. 517/424-8900 ■ Fax 517/423-6827
www.milacron.com
The Impact Trimmer Drive
Impact trimmers are traditionally equipped with standard motor starters and belt sheaves sized to
provide a trimmer with one speed. This means the trimmer must run faster than the blow molder and
then stop and wait as the next set of bottles is loaded.
With a VF Drive, the trimmer speed can be slowed down to more closely match the machine cycle
time. In some cases the trimmer dwell time can be eliminated all together making it possible to run
without cycling the trimmer brake.
Benefits Include:
 Slower trimmer speeds required
 Matched machine and trimmer cycle times
 Reduced wear on brake
 Reduced wear on trimmer drive components
 Energy savings
The Cooling Bed Drive
Cooling beds are also normally equipped with only a motor starter, motor and gearbox. Cooling bed
operation can be jerky and inconsistent with variation in speed and stopping position.
A VF Drive provides smoother more consistent operation with reduced wear on drive components.
Benefits Include:
 Smoother ramped starts
 More consistent stops
 Optimized speed control
 Energy savings
SELECTING THE CORRECT DRIVE FOR YOUR EXTRUDER
Step 1: Gather Pertinent Information
The following information is required in order to correctly select the optimum drive size and configuration
for your application:
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Machine Serial Number
Machine Model Number
Electrical Schematic Number
Number of Heads
Maximum Gram Weight of Container with Flash
Current Extruder Drive Type
Current Extruder Screw Type
Minimum Expected Cycle Time
Step 2: Calculate the Horsepower Required
The correct horsepower can be determined by inserting your operating conditions into the formula
below. This formula calculates the plastic thruput requirement based on bottle weight, cycle time, and
the number of heads.
(# of Heads) x (Cont. wt. w/Flash) x (60/Cycle Time) x (60/454) = lbs/Hour
Now, choose a drive horsepower from Table 1, taking into consideration what screw type you currently
have in the machine.
Example:
If you have a 350R2, 6 head machine that is running a 98 gram container with flash at a 7.5 second
cycle time, then:
(6) x (98) x (60/7.5) x (60/454) = 622 lbs/Hour is your required thruput
Table 1 Maximum Thruputs
Screw Size
(Dia.)
2.5
3.5
3.5
3.5
Drive Size
(HP)
50
75
100
125
General Purpose
(lbs/hr)
275
480
600
650
R2000 Style
High Output
(lbs/hr)
325
625
780
845
Based on Table 1 you could choose:
 125hp drive with a new or existing General Purpose screw
 75hp drive with a new or existing High Output screw
 100hp drive with a new or existing High Output screw
 125hp drive with a new or existing High Output screw
What you really want to know is which Drive and Screw combination is most cost effective!
Step 3: Choose the Most Cost Effective Solution
Table 2 contains annual energy consumption costs for each drive size based on plastic thruput required.
This energy cost is calculated assuming 6000 hours of operation and $0.08 per kilowatt hour.
To determine the most cost effective drive solution, find the plastic thruput requirement in the left hand
column of Table 2. Follow the appropriate row across from left to right and identify the most cost effective
drive horse power and screw combination by choosing the smallest dollar figure in that row.
Table 2 Annual Energy Consumption Costs
THRUPUT
LBS/HR
225
275
300
325
350
400
480
500
550
600
625
650
780
845
50 HP
$14,371
$17,581
GP SCREW
75 HP
100 HP
$15,474
$16,717
$18,038
$20,615
$24,746
$23,386
$24,339
$26,771
$29,207
125 HP
R2000 STYLE HIGH OUTPUT SCREW
50 HP
75 HP
100 HP
125 HP
$12,189
$14,875
$16,257
$17,565
$15,836
$19,010
$19,784
$21,762
$23,741
$24,737
$27,270
$28,382
$31,218
$34,058
$35,487
$36,886
$20,626
$22,502
$23,446
$24,370
$29,240
$26,198
$27,297
$28,374
$34,044
$36,896
Note: The energy costs shown here for the 75, 100, and 125HP drives are calculated based on 350R
extruders. The 50HP drive is utilized exclusively on the 250R1.
Back to the example
A 350R2 machine with a 6 head running a 98 gram bottle with flash at a 7.5 second cycle must produce
622 lbs/hr of plastic.
Using Table 2, you can see that a machine with a 100hp ACVF Drive and a High Output screw can
produce 622 lbs/hr most efficiently. This setup would consume just under $23,446 in drive energy
compared to just under $35,487 for the 125hp drive and general purpose screw.
Step 4: See If Your Local Power Company Will Share in Your Upgrade Cost
Many local power companies offer rebates for converting your drive components to a more efficient
technology. The Uniloy package offers a Premium Efficiency motor. The following chart shows the
motor efficiencies only. This information is typically required by power companies in order to consider
your rebate request.
50 Hp
94.1%
75 Hp
94.5%
100 Hp
95.0%
125 Hp
95.4%
THE UNILOY ACVF DRIVE RETROFIT PACKAGES INCLUDE:
Extruder Drive Package
 Drive Controller
 Premium Efficiency Motor
 RPM and Load Meters
 Rotary Speed Potentiometer
 Door Interlock
 Mounting Materials
 Sheaves
 Motor Bushing
 Miscellaneous Seal Tight, Connectors, Wire
 OEM Technical Support of Field Proven Components
 Complete Engineering
 Installation Instructions
 Electrical Schematics
Trimmer Drive Package
 Drive Controller
 Inverter Duty Brake Motor
 Mounting Materials
 Sheaves
 Timing Belt
 Miscellaneous Seal Tight, Connectors, Wire
 OEM Technical Support of Field Proven Components
 Complete Engineering
 Installation Instructions
 Electrical Schematics
Cooling Bed Drive Package
 Drive Controller
 Inverter Duty Motor
 Mounting Materials
 Miscellaneous Seal Tight, Connectors, Wire
 OEM Technical Support of Field Proven Components
 Complete Engineering
 Installation Instructions
 Electrical Schematics
Sales and Service
For more information on these upgrades, please contact your local Uniloy Parts Sales Representative.
Trained Uniloy Service Representatives are available to assist in the installation of these packages at
your facility.